Volkswagen Type II Transporter 1200 Series Shop Manual page 139

NOTE: The threads of the retainers should be lightly
coated with lithium base grease.
(6) If removed, instal the reverse gear on the front end
of the rear main drive shaft, screw the shaft onto the rear
end of the front main drive shaft, back off the rear shaft by
one spline and slide the reverse gear forward and instal a
new circlip.
NOTE: The teeth of the reverse gear must be to the
forward end of the ?ear sleeve.
(7) Using a new gasket, instal the clutch housing on the
open end of the transmission case and secure with spring
washers and nuts tightened to 14ft/lb.
(8) With 4th gear engaged, rotate the ring gear and
differential carrier bearings by turning the main drive shaft
to properly seat the bearings at the same time tightening
the right hand side retaining ring to the position as marked
on dismantling. In this way the ring gear backlash and
carrier bearing preload should be the same as before
removing the ring gear and differential assembly.
Transmission and Rear Axle-58
NOTE: Coat the machined and thrP.aded faces of the
retaining rings and the gear case with a suitable sealer to
prevent co"osion of the exposed threads.
(9) Instal the multi-hex locking plate in each retainer
ring and secure each plate with two Philips screws.
(10) Instal the spacer washers and drive shaft flanges
on the side gear shafts and fit new circlips.
NOTE: If difficulty is experienced in seating the eire/ips in
the groove in the shaft, use special bridge VW 201 with
suitable stud to draw the flange down against the spacer
washer.
(11) Press new seal caps into the centre of the drive
flanges.
TO ADJUST DIFFERENTIAL SIDE GEAR END FWAT
If any of the differential components are replaced, it is
important that the side gear end float is correctly
maintained, by installing a spacer sleeve of the correct
length. Four different sleeve lengths are available.
{1) Place the short shaft and side gear with thrust
washer in the short half of the differential housing and
clamp the gear down hard against the
fac~
of the housing.
(2) Place the long shaft side gear and thrust washer in
the long half of the differential housing and, with the
shortest of the spacer sleeves in position on the upper face
of the short side gear and shaft, place the long shaft side
DIFFERENTIAL SHAFT AND SPACER
EXPANSION PLUG
PINION AND THRUST WASHER
~,IDE
GEAR
I
7RUST WASHER
LOCK PIN / )
CIRCLIP
THRUST WASHER
DRIVE FLANGE
DIFFERENTIAL CASE -
....
Components of Differential Case and Carrier Bearings with
Screw Type Bearing Adjustment.
Measuring Length of Spacer Sleeve when Adjusting
~
Differential Side Gear End Float.
139